Skip to main content
SpringerLink
Log in

Theoretical modeling and experimental study on grinding force of straight groove structured grinding wheel

  • Original Article
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Structured grinding wheel has obvious advantages in reducing grinding force, and the structural parameters of grinding wheel have important influence on the reduction of grinding force. In order to determine the influence law of structural parameters on grinding force, the following theoretical modeling and experimental research work are carried out in this paper. Firstly, single grit scratching experiments of the workpiece material are carried out to determine the critical cutting depth for ploughing and cutting transition. The influences of structural parameters on the maximum undeformed chip thickness and the average contact arc length during grinding are analyzed in detail. The abrasive grains are simplified into a cone with an apex angle of 120°, the surface topography model of the structured grinding wheel is established according to the measured results of the distribution law of abrasive grains on the surface of the grinding wheel and the structural characteristic parameters. Combined with the grinding force model of single abrasive grain in ploughing and cutting stages, the grinding force calculation model of straight groove structured grinding wheel is established during the grinding process. Finally, grinding experiments are carried out to verify the accuracy of the theoretical grinding force model. The results show that the calculated values of grinding force are in good agreement with the experimental values, and the maximum calculation errors of tangential grinding force and normal grinding force are 14.5% and 11.8%, respectively. It is found that when the intermittent ratio of structured grinding wheel is constant, the groove width has little influence on grinding force. However, when the groove width is constant, the intermittent ratio has a great influence on the grinding force, and with the increase of the intermittent ratio, the grinding force decreases obviously.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16

Similar content being viewed by others

Data availability

All data generated or analysed during this study are included in the present article.

References

  1. Jamshidi H, Budak E (2020) An analytical grinding force model based on individual grit interaction. J Mater Process Technol 283:116700–116714. https://doi.org/10.1016/j.jmatprotec.2020.116700

    Article  Google Scholar 

  2. Malkin S (1989) Grinding technology: theory and application of machining with abrasives. Ellis Harwood Publication, UK

    Google Scholar 

  3. Hecker RL, Ramoneda IM, Liang SY (2003) Analysis of wheel topography and grit force for grinding process modeling. J Manuf Process 5(1):13–23. https://doi.org/10.1016/S1526-6125(03)70036-X

    Article  Google Scholar 

  4. Tang JY, Du J, Chen YP (2009) Modeling and experimental study of grinding forces in surface grinding. J Mater Process Technol 209(6):2847–2854. https://doi.org/10.1016/j.jmatprotec.2008.06.036

    Article  Google Scholar 

  5. Jamshidi H, Gurtan M, Budak E (2019) Identification of active number of grits and its effects on mechanics and dynamics of abrasive processes. J Mater Process Technol 273:116239–116250. https://doi.org/10.1016/j.jmatprotec.2019.05.020

    Article  Google Scholar 

  6. Durgumahanti USP, Singh V, Rao PV (2010) A new model for grinding force prediction and analysis. Int J Mach Tools Manuf 50(3):231–240. https://doi.org/10.1016/j.ijmachtools.2009.12.004

    Article  Google Scholar 

  7. Hou ZB, Komanduri R (2003) On the mechanics of the grinding process – part I. Stochastic nature of the grinding process. Int J Mach Tools Manuf 43(15):1579–1593. https://doi.org/10.1016/S0890-6955(03)00186-X

    Article  Google Scholar 

  8. Jiang JL, Ge PQ, Zhang Y, Wang DX (2012) A mathematical model of single grain forces in grinding process. Appl Mech Mater 229-231:1904–1907. https://doi.org/10.4028/www.scientific.net/AMM.229-231.1904

    Article  Google Scholar 

  9. Jiang JL, Ge PQ, Sun SF, Wang DX, Wang YL, Yang Y (2016) From the microscopic interaction mechanism to the grinding temperature field: an integrated modelling on the grinding process. Int J Mach Tools Manuf 110:27–42. https://doi.org/10.1016/j.ijmachtools.2016.08.004

    Article  Google Scholar 

  10. Li HN, Yu TB, Wang ZX, Zhu LD, Wang WS (2017) Detailed modeling of cutting forces in grinding process considering variable stages of grain-workpiece micro interactions. Int J Mech Sci 126:319–339. https://doi.org/10.1016/j.ijmecsci.2016.11.016

    Article  Google Scholar 

  11. Zhang YB, Li CH, Ji HJ, Yang XH, Yang M, Jia DZ, Zhang XP, Li RZ, Wang J (2017) Analysis of grinding mechanics and improved predictive force model based on material-removal and plastic-stacking mechanisms. Int J Mach Tools Manuf 122:81–97. https://doi.org/10.1016/j.ijmachtools.2017.06.002

    Article  Google Scholar 

  12. Walter C, Komischke T, Kuster F, Wegener K (2014) Laser-structured grinding tools–generation of prototype patterns and performance evaluation. J Mater Process Technol 214(4):951–961. https://doi.org/10.1016/j.jmatprotec.2013.11.015

    Article  Google Scholar 

  13. Mohamed AMO, Bauer R, Warkentin A (2013) Application of shallow circumferential grooved wheels to creep-feed grinding. J Mater Process Technol 213(5):700–706. https://doi.org/10.1016/j.jmatprotec.2012.11.029

    Article  Google Scholar 

  14. Dai CW, Yin Z, Ding WF, Zhu YJ (2019) Grinding force and energy modeling of textured monolayer CBN wheels considering undeformed chip thickness nonuniformity. Int J Mech Sci 157:221–230. https://doi.org/10.1016/j.ijmecsci.2019.04.046

    Article  Google Scholar 

  15. Guo ZZ, Cheng J, Wu J, Zhang XF, Liu BY (2022) Modeling and experimental study on the grinding performance of precision diamond grinding tool with defined texture. Int J Adv Manuf Technol 1-22. https://doi.org/10.1007/s00170-021-08372-w

  16. Li C, Piao Y, Meng B, Hu Y, Li L, Zhang F (2021) Phase transition and plastic deformation mechanisms induced by self-rotating grinding of GaN single crystals. Int J Mach Tools Manuf 172:103827. https://doi.org/10.1016/j.ijmachtools.2021.103827

    Article  Google Scholar 

  17. Öpöz TT, Chen X (2015) Experimental study on single grit grinding of Inconel 718. Proc Inst Mech Eng Part B: J Eng Manuf 229(5):713–726. https://doi.org/10.1177/0954405414531114

    Article  Google Scholar 

  18. Setti D, Kirsch B, Aurich JC (2019) Experimental investigations and kinematic simulation of single grit scratched surfaces considering pile-up behaviour: grinding perspective. Int J Adv Manuf Technol 103(1):471–485. https://doi.org/10.1007/s00170-019-03522-7

    Article  Google Scholar 

  19. Liu YM, Gong YD, Cao ZX (2012) Analysis of numerical grinding wheel topology and experimental measurement. J Mech Eng 48(23):184–190. https://doi.org/10.3901/JME.2012.23.184

    Article  Google Scholar 

  20. Ni J, Feng K, Al-Furjan MSH, Xu XJ, Xu J (2019) Establishment and verification of the cutting grinding force model for the disc wheel based on piezoelectric sensors. Sensors 19(3):725–738. https://doi.org/10.3390/s19030725

    Article  Google Scholar 

  21. Li BK, Dai CW, Ding WF, Yang CY, Li CH, Kulik O, Shumyacher V (2021) Prediction on grinding force during grinding powder metallurgy nickel-based superalloy FGH96 with electroplated CBN abrasive wheel. Chin J Aeronaut 34(8):65–74. https://doi.org/10.1016/j.cja.2020.05.002

    Article  Google Scholar 

  22. Li DG, Tang JY, Chen HF, Shao W (2019) Study on grinding force model in ultrasonic vibration-assisted grinding of alloy structural steel. Int J Adv Manuf Technol 101(5):1467–1479. https://doi.org/10.1007/s00170-018-2929-2

    Article  Google Scholar 

  23. Gao Y, Wang FW, Liang Y, Han J, Su J, Tong Y, Liu L (2021) Cutting performance of randomly distributed active abrasive grains in gear honing process. Micromachines 12(9):1119–1135. https://doi.org/10.3390/mi12091119

    Article  Google Scholar 

  24. Merchant ME (1945) Mechanics of the metal cutting process. I. Orthogonal cutting and a type 2 chip. J appl phys 16(5):267–275. https://doi.org/10.1063/1.1707586

    Article  Google Scholar 

  25. Chen JY, Shen JY, Huang H, Xu X (2010) Grinding characteristics in high speed grinding of engineering ceramics with brazed diamond wheels. J Mater Process Technol 210(6–7):899–906. https://doi.org/10.1016/j.jmatprotec.2010.02.002

    Article  Google Scholar 

  26. Xu XP, Li Y, Malkin S (2001) Forces and energy in circular sawing and grinding of granite. J Manuf Sci Eng 123(1):13–22. https://doi.org/10.1115/1.1344900

    Article  Google Scholar 

Download references

Funding

This project is supported by the National Natural Science Foundation of China (Grant No. 51905168), Natural Science Foundation of Hunan Province (Grant No. 2020JJ5192), and Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material (Hunan University of Science and Technology) (Grant No. E21848).

Author information

Authors and Affiliations

  1. Hunan Provincial Key Laboratory of High Efficiency and Precision Machining of Difficult-to-Cut Material, Xiangtan, 411201, China

    Jun Yi, Hui Deng, Bing Chen & Wei Zhou

  2. College of Mechanic Engineering, Hunan University of Science and Technology, Xiangtan, 411201, China

    Jun Yi, Tao Yi, Hui Deng, Bing Chen & Wei Zhou

Authors
  1. Jun Yi
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Tao Yi
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Hui Deng
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Bing Chen
    View author publications

    You can also search for this author in PubMed Google Scholar

  5. Wei Zhou
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

Yi Jun: conceptualization, methodology, supervision, and manuscript revision. Yi Tao: investigation, experimentation and data collection, data curation, and writing the original draft. Chen Bing: resources and funding acquisition. Deng Hui: original draft revision and review. Zhou Wei: writing review and editing.

Corresponding author

Correspondence to Jun Yi.

Ethics declarations

Ethics approval

Not applicable.

Consent to participate

Not applicable.

Consent for publication

Not applicable.

Conflict of interest

The authors declare no competing interests.

Additional information

Publisher's note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Yi, J., Yi, T., Deng, H. et al. Theoretical modeling and experimental study on grinding force of straight groove structured grinding wheel. Int J Adv Manuf Technol 124, 3407–3421 (2023). https://doi.org/10.1007/s00170-022-10747-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-022-10747-6

Keywords

Search

Navigation